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S E R I E S O F M E T E R I N G P U M P S

DUAL SEAL PLUNGER

V

INSTALLATION, OPERATION& MAINTENANCE MANUAL

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P125V125P250V225P250V300

P500V225P500V300P500V400(1)

P750V400(1)

P1000V400(1)

P1000V600(1)

P1000V800(1)

NOTE: (1)The 400, 600 and 800 motor cylinders are only available with the CR (controller-relay) or SR (solenoid-relay) control methods.

CR P1000V800 A PE

C: ControllerCR: Controller - Relay

S: Solenoid ValveSR: Solenoid Valve - Relay

Control

Method

BasicModel(2)

A: 17-4 phB: 316 SS

CR: Ceramic

PlungerMaterial

PE: Polyethylene (UHMW)TC: Teflon Composite

TG: Teflon GraphiteV: Viton

BR: Buna NK: Kalrez

EPR: Ethylene Propylene

SealMaterial

PART NUMBER DESIGNATION

S E R I E S O F M E T E R I N G P U M P SDUAL SEAL PLUNGER

V

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TABLE OF CONTENTS

Section Description Page

1.0 FUNCTIONAL DESCRIPTION 1

1.1 Physical Description 1

1.2 Capabilities 3

1.3 General Operating Sequence 9

2.0 INSTALLATION OF PUMP AND CONTROLLER 10

2.1 General 10

2.2 Pump Assembly 10

2.3 Typical Installation 11

2.4 Supply Reservoir 11

2.5 Relief Valve11

3.0 START UP, OPERATION & SHUTDOWN 11

3.1 General 11

3.2 Startup 11

3.3 Operation 12

3.4 Shutdown and Storage 12

4.0 MAINTENANCE 12

4.1 General 12

4.2 Disassembly and Assembly 13

4.3 Preventive Maintenance 23

4.4 Troubleshooting 23

5.0 PARTS LIST AND REPAIR KIT ORDERING REFERENCE 26

5.1 Controller Part Lists and Repair Kits 26

5.2 Relay Part Lists and Repair Kits 26

6.0 LIMITED WARRANTY 26

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SECTION 1.0: FUNCTIONAL

DESCRIPTION

1.1 PHYSICAL DESCRIPTION

The letters CP at the beginning of a pump

assembly model number mean that the

model consists of a controller (C) and

pump (P) For example: CP125V125,

CP250V225, CP250V300, CP500V225, and

Control Methods For The Pump

1

1.1.1 Controller

The controller, consisting of an upper and

lower chamber separated by a sliding

spool, uses a capillary tube with a needle

valve to transfer the supply air/gas from

the lower to the upper chamber. When the

sliding spool is in its highest position, a

pilot plug closes a vent and moves the

supply air/gas to the pump or relay. In the

spools lowest position, the reverse is true;

the pilot plug prevents supply air/gas from

CP500V300. The letters CRP mean that the

model also has a relay (R). For example:

CRP500V400, CRP750V400, CRP1000V400,

CRP1000V600, and CRP1000V800.

Some pumps use different relay sizes:

CRP500V400, CRP750V400,CRP1000V400, and CRP1000V600

pumps use the PO3-6S relay.

CRP1000V800 pump uses the PO4-6S

relay.

The PNEUMATIC RELAY is a pilot operated valve designed to provide the higher

air or gas flow rates necessary for PNEUMATIC DRIVE CYLINDER

diameters greater than 3 inches. The PNEUMATIC RELAY is actuated by the pulses produced by

the CONTROLLER. A single acting PNEUMATIC RELAY is used with pumps that have return springs as illustrated to the left.

The air or gas pressure is required to return the PISTON-PLUNGER ASSEMBLY on the CRP1000V800. Therefore a double

acting PNEUMATIC RELAY is required, illustrated to the right.

The MK XIIA Controller operates on the same operating principal as the MK X Controller.

The MK XIIA has the same upper and lower chambers, but are separated with flexible

diaphragms rather than sliding seals. A capillary tube, controlled by a needle valve,

transfers the air/gas supply to the pump from the lower to the upper chamber.

When the spool is in the highest position, a pilot plug closes a vent and opens thesupply air/gas to the pump. When the spool is in its lowest position, the pilot plug

prevents the supply air/gas from entering the pump, and opens the air/gas vent to let it

exhaust the pump. The spool then returns to its highest position to repeat the process.

1. Oscillamatic Controller

STROKE RATECONTROL KNOB

NEEDLE VALVE

CONTROL SPOOL

AIR/GAS SUPPLYTO CONTROLLER

SUPPLY TO PUMP1/4 NPT

EXHAUST VALVE

OPTIONAL3-15CONTROL PORT(MK XIIB) 1/8 NPT

CONTROLAIR PASSAGE

UPPER DIAPHRAGM

MIDDLE DIAPHRAGM

LOWER DIAPHRAGM

SUPPLY VALVE

EXHAUSTFROMPUMP

1/4 NPT

3. Solenoid Valves

The pumps can be automated by replacing the

CONTROLLER with a 3-way electro-pneumatic

SOLENOID VALVE. The SOLENOID VALVE can be

cycled in order to achieve the desired pump output.

Flow tracking can be accomplished by having a

FLOWMETER or PH METER signal interpreted by our

WPC9001 or a PLC. The typical arrangement for a

WPC-9001 installation is shown at right.

CONTROLLER

PO3-6S RELAY

CONTROLLER

P04-6S RELAY

PILOT PULSES FROMCONTROLLER

EXHAUST

SINGLE ACTINGPO3-6S DOUBLE ACTING

PO4-6S

PUMP

SUPPLYPRESSURE(REAR)

SUPPLY PRESSURE

EXHAUST NO. 1

PUMP POWERSTROKE NO. 1

PUMP RETURNSTROKE NO. 2

EXHAUST NO. 2

PUMP INSTALLATIONCRP500V400,CRP750V400

CRP1000V400CRP1000V600

PUMP INSTALLATIONCRP1000V800

PILOT PULSESFROM CONTROLLER

2. Controller-Pneumatic Relay Combination

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At the time the controller or relay exhausts

the air/gas, if the pump has a motor return

spring, fluid pressure in the fluid chamber

and the motor return spring force the

piston plunger upwards. If the pump has

no motor return spring, supply pressure

from a relay enters beneath the piston to

help force the piston/plunger assembly

upwards. In either case, the plunger

assembly stops when the piston contacts

the end of the stroke adjuster.

The piston face area where the air/gas

pressure is applied is much greater than

the plunger face area, which works against

the pressure of the process fluid. This area

ratio, called the amplification ratio,

allows the pump to work against process

fluid pressures much greater than the

air/gas supply pressure.

Note: process pressure + 200psi /required air supply = amplification ratio

air/gas pressure. This relay has two poppet

valves. The upper valve operates in the

same way as the PO3-6S relay valves,

while the lower valve operates in the

opposite order. That is, when the upper

valve applies air/gas pressure to the pump,

the lower valve exhausts it, and when the

upper valve exhausts the air/gas, the lower

valve applies pressure to the opposite side

of the piston.

1.1.3 Pumps

The pneumatic V Series metering plunger

pump consists of a body, fluid chamber,

and a motor cylinder or air chamber,

separated by a piston/plunger assembly

and seals. In the fluid chamber, the inlet

(suction) and discharge (outlet) ports have

check valves that control the direction of

the fluid flow. In the motor cylinder, the

air/gas supplied from the controller or relay

enters and exhausts through a pipe nipple

that connects the controller or relay to the

motor cylinder.

35 TO

100 PSIG

50 TO

150 PSIG

CONTROLLER

RELAY

DISCHARGE CHECK VALVE

SUCTION CHECK VALVE

35 TO

100 PSIG

CONTROLLER

DISCHARGE

CHECK VALVE

SUCTION CHECK VALVE

35 TO

100 PSIG

50 TO

150 PSIG

CONTROLLER

RELAY

SUCTION CHECK VALVE

DISCHARGE CHECK VALVE

TYPICAL CRP1000V800(WITH PO4-6S RELAY)

TYPICAL CRP500V400, CRP750V400, CRP1000V400 & 600(WITH PO3-6S RELAY)

TYPICAL CP125V, CP250V, CP500V(WITH 125, 225 & 300 CYLINDERS)

2

entering pump or relay, and opens the vent

to let it exhaust. The spool then returns to

its highest position and repeats the cycle.

1.1.2 Relays

A relay is a pilot operated servo valve.

Air/gas pressure from a controller forces apiston and one or more attached poppet

valves to move. Then, when the controller

removes the pressure, a spring forces both

the piston and poppet valve(s) in the

reverse direction.

Relay models differ in operation. The

PO3-6S relay has one poppet valve that

connects the supply air/gas to the pump

and blocks the exhaust when the controller

applies air/gas pressure to the relay piston.

When the controller removes pressure

from the piston, the poppet valve stops the

supply air/gas and connects the pump to

the exhaust.

The PO4-6S relay, used on pumps that do

not have a motor return spring, drives the

air piston both up and down with the

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1.2.1.1 Controller Supply Pressure

Controllers will operate with the following

supply pressures:

Maximum Minimum

psi bar psi bar

MK XII 100 6.9 35 2.4

To establish the proper air/gas supply

pressure for the controller or relay, add

200 psig or 13.8 barg to the process

pressure the pump is working against.

Then use the performance graphs located

in section 1.2.2.2.

Remember for a controller-relay

combination the controller supply pressure

need only be set at the minimum pressure

of 35 psig or 2.4 barg. The relay supply

would be established in the above

procedure or refer to section 1.2.1.2.

CAUTION: To prevent damage to the

controller, always use a regulator

between the supply and the controller

when the air/gas supply pressure is

more than the maximum rating of your

controller.

1.2.1.2 Relay Supply Pressure

Relays, which require a separate air

supply, operate with supply pressuresbetween 35 psig (2.41 bar) and 150 psig

(10.3 bar). The supply pressure must be 35

psig minimum or equal to or greater than

the process pressure plus 200 psi, divided

by the pump amplification ratio. (EXAMPLE:

CRP1000V400 @ 1000 PSI + 200 PSI

divided by 15.38 = 78 air supply required.

Refer to section 1.1.3 for the amplification

ratio formula) When using a controller/relay

combination, hold the air/gas supply

pressure to the controller to the minimum

value of 35 psig, and the relay at 35 psig

minimum.CAUTION: To prevent damage to the

relay, always use a regulator between

the supply and the relay when the

supply pressure is more than 150 psig

(10.3 bar).

1.2 CAPABILITIES

1.2.1 Controllers and Relays

Controllers and relays will require separate

supply sources, and fortunately will

operate with air or any gas, such as carbon

dioxide, nitrogen or natural gas.

WARNING: TO PREVENT INJURY, MAKE

SURE THAT ANY FLAMMABLE GAS

SUCH AS NATURAL GAS IS PROPERLY

VENTED FOR SAFETY.

CAUTION: If the gas could possibly

damage the standard elastomeric

material, please contact your

distributor or Williams Instrument

Incorporated for advice.

To increase the process fluid flow rate, two

or more pumps can be multiplexed: their

inlets and outlets connected in parallel.

1.2.2 Pumps

1.2.2.1 Flow Pressure Performance Table*:

MAX MAX AIR CONSUMPTIONMODEL MAX VOLUME STROKE STROKES DISCHARGE 100 6.9 150 10.3@ AIR/GAS VOLUME PER LENGTH PER MINUTE PRESSURE PSIG BAR PSIG BARSUPPLY PRESSURE STROKE (RANGE) SCF SCM SCF SCM

GPH/LPH CC INCH PSIG /BARG PER DAY PER DAY PER DAY PER DAY

CP125V125

@ 100 PSI/6.9 BAR .07 /.27 .1 .5 1-45 8650 / 596.4 180 5

CP250V225

@ 100 PSI/6.9 BAR .57 /2.16 .8 1 1-45 7200 / 496.4 1163 33

CP250V300

@ 100 PSI/6.9 BAR .57 /2.16 .8 1 1-45 13,100 / 903.2 2068 59

CP500V225

@ 100 PSI/6.9 BAR 2.26 /8.55 3.2 1 1-45 1750 / 120.7 1163 33

CP500V300

@ 100 PSI/6.9 BAR 2.26 /8.55 3.2 1 1-45 3250 / 224.1 2068 59

CRP500V400

@ 100 PSI/6.9 BAR 2.26 /8.55 3.2 1 1-45 6300 / 434.4 3676 104@ 150 PSI/10.3 BAR 2.26 /8.55 3.2 1 1-45 9200 / 634.3 5280 150

CRP750V400

@ 100 PSI/6.9 BAR 5.00 /18.9 7.0 1 1-45 2600 / 178.3 3676 104 5280 150@ 150 PSI/10.3 BAR 5.00 / 18.9 7.0 1 1-45 4000 / 275.8

CRP1000V400

@ 100 PSI/6.9 BAR 9.08 /34.37 12.7 1 1-45 1520 / 104.8 3676 104@ 150 PSI/10.3 BAR 9.08 /34.37 12.7 1 1-45 2300 / 158.6 5280 150

CRP1000V600

@ 100 PSI/6.9 BAR 9.04 /34.22 12.6 1 1-45 3400 / 234.4 8273 234@ 150 PSI/10.3 BAR 7.00 /26.50 9.8 1 1-35 4700 / 324.0 9239 262

CRP1000V800

@ 100 PSI/6.9 BAR 8.81 /33.35 12.3 1 1-45 6300 / 434.4 14707 416@ 150 PSI/10.3 BAR 6.82 /25.81 9.5 1 1-35 9100 / 627.4 16426 465

*This data should only be used to provide you with an initial size selection. You must refer to the actual performance graphs in order to verify your pump selection.

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4

1.2.2.2 Using The Graphs*

Use the following Performance Flow Curves* in order to:

1) Determine the flow capability of the pump you have selected.If you have sized the pump too close to the upper or lower strokerate limit, you may wish to change to a different pump size. Of

course you can also change your flow for a given stroke rate byadjusting the stroke length. Example:

2) Determine the air pressure necessary to provide the desiredpump discharge pressure.

A) The flow curves show the maximum flow/pressure limit of the pumps.The upper near horizontal line represents the maximum flow capability

(45 SPM @ 100% stroke). The near vertical lines represent themaximum discharge pressure at the corresponding air/gas pressure.The area under the curve represents the entire flow/pressure range forthe pumps.

B) THE GRAY CURVE defines the relationship between air/gas supplypressure and discharge pressure. For each discharge pressure thereis a minimum air/gas supply pressure required. Always add 200 PSIto your discharge pressure in order to ensure positive injection.Find the discharge pressure on the horizontal axis and follow it up tothe red curve. At that point, read your air/gas pressure requirementson the right axis in PSIG. The minimum air/gas supply pressure willproduce discharge pressures found to the left of the 35 PSIG limit line.

The required air/gas supply pressure can be read off the graph by firstadding 200 psi to the discharge pressure. Then locate the psi on thedischarge pressure axis and follow it up until it intersects the red line.Follow this point to the air/gas supply pressure axis on the right and youwill find the appropriate air/gas pressure necessary to operate the pump.

These Settings Will Produce The Same Pump Flow Rate

STROKE RATE STROKE LENGTH

10 1 (100%)20 1/2 (50%)40 1/4 (25%)

The performance curve graph illustrated here is, in fact, two

graphs overlayed upon each other. The first, determines theair/gas pressure, illustrated in gray. The second, determinesyour discharge pressure, shown in black. Where these twooverlayed graphs intersect define your optimum flow range.

0 1000 2000 3000 4000 5000 6000 7000 8000 9000

0.09

0.08

0.07

0.06

0.05

0.04

0.03

0.02

0.01

0.00

FLOW

-GPH

STROKE LENGTH: 100% PLUNGER SPEED: 45 SPM

DISCHARGE PRESSURE - PSIG

100

80

60

40

20

0

AIR/GASPRESSUREPSIG

35

1 0 0

P S I G A

I R / G A S

35PSI GAI R/G

AS

0.054

50

MAXFLOW(GPH)

Reading The Graphs

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0 1000 2000 3000 4000 5000 6000 7000 8000 9000

0.09

0.08

0.07

0.06

0.05

0.04

0.03

0.02

0.01

0.00

FLOW

-GPH



100

80

60

40

20

0

AIR/GASPRESSUREPSIG

35

1 0 0 P S I G

A I R / G

A S

35

PSIG A

IR/ G

AS

0.054

50

MAXFLOW(GPH)

AIR/GAS

PRE

SSUR

E

0.80

0.70

0.60

0.50

0.40

0.30

0.20

0.10

0.00

FLOW

-GPH

0 1000 2000 3000 4000 5000 6000 7000 8000

100

80

60

40

20

0

AIR/GASPRESSUREPSIG

35


35PSIG AIR

100PSIGAIR


MAXFLOW(GPH)

AIR/

GASPR

ESSU

RE

5

0 1500 3000 4500 6000 7500 9000 10500 12000 13500 15000

90

100

80

70

60

50

40

30

35

20

10

0

0.90

1.00

0.80

0.70

0.60

0.50

0.40

.030

0.20

0.10

0

FLOW

-GPH



AIR/GASPRESSUREPSIG

100PSIGAIR/G

AS

AIR

/GASPRES

SURE

MAXFLOW(GPH)

35PSIGAIR/GAS

CP125V125

Discharge Pressure PSI 0 500 1000 1900 5000 8500Gph .069 .066 .063 .059 .043 .025Air Pressure PSI 35 35 35 35 62 98

CP250V225

Discharge Pressure PSI 0 500 1000 1900 5000 6600gph .57 .565 .557 .552 .520 .502Air Pressure PSI 35 35 35 35 70 90

CP250V300

Discharge Pressure PSI 0 1000 3000 6000 10000 11000gph .522 .502 .462 .402 .321 .301Air Pressure PSI 35 35 35 47 77 85

Performance Flow Curves

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160

140

120

100

80

60

40

20

150

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

2.50

2.25

2.00

1.75

1.50

1.25

1.00

0.75

0.50

0.25

0.00


FLOW

-GPH

AIR/GASPRESSURE-PSIG

35

3 5

P S

I G A I R / G

A S

100PSIGAIR/GAS

150PSIGA

IR/G

AS


MAXFLOW(GPH)

AIR/GA

SPR

ESSU

RE

100

90

80

70

60

50

40

30

20

10

0 200 400 600 800 1000 1200 1400 1600 1800 2000

2.50

2.25

2.00

1.75

1.50

1.25

1.00

0.75

0.50

0.25

0.00


FLOW

-GPH


35


100PSIGAIR/G

AS

3 5

P S

I G A

I R / G

A S

MAXFLOW(GPH)

AIR

/GASPRES

SURE

0 500 1000 1500 2000 2500 3000 3500

3.00

2.75

2.50

2.25

2.00

1.75

1.50

1.25

1.00

0.75

0.50

0.25

0.00


100

90

80

70

60

50

40

30

20

10

0

AIR/GASPRESSUREPSIG

35

FLOW

-GPH

PLUNGER SPEED: 45 SPM

100PSIG

35PSIG

MAXFLOW(GPH)

AIR/GAS

PRE

SSURE

CP500V225

Discharge Pressure PSI 0 200 450 1000 1400 1500gph 2.26 2.26 2.26 2.23 2.21 2.21Air Pressure PSI 35 35 35 60 82 88

CRP500V400

Discharge Pressure PSI 0 1500 3000 5000 7000 8100Gph 2.26 2.20 2.15 2.07 1.99 1.96Air Pressure PSI 35 35 52 80 110 130

CP500V300


Performance Flow Curves (cont.)

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7

160

180

200

140

120

100

80

60

40

50

20

150

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

10.00

9.00

8.00

7.00

6.00

5.00

4.00

3.00

2.00

1.00

0.00


FLOW

-GPH


50

PSIGAIR/ GAS

100PSIGAIR/GAS

150PSIGAIR/G

AS


MAXFLOW(GPH)

AIR/GAS

PRE

SSUR

E

160

140

120

100

80

60

40

20

150

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

10.00

9.00

8.00

7.00

6.00

5.00

4.00

3.00

2.00

1.00

0.00


FLOW

-GPH


125

35

3 5

P S I G

A IR

/G A S

150PSIGAIR/GAS

STROKE LENGTH: 100% PLUNGER SPEED: 45 SPM & 35 SPM @ 150 PSIG

1 00P

SIG

AIR/G

AS

125PSIGAIR/GAS

MAXFLOW(GPH)

AIR/GAS

PRE

SSUR

E

160

140

120

100

80

60

40

20

150

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

10.00

9.00

8.00

7.00

6.00

5.00

4.00

3.00

2.00

1.00

0.00


FLOW

-GPH


125

35

35PSIGAIR/ G

AS

STROKE LENGTH: 100% PLUNGER SPEED: 45 SPM & 35 SPM @ 150 PSIG

125PSIGAIR/GAS

100PSIGAIR/GAS

150PSIGAIR/G

AS

MAXFLOW(GPH)

AIR/GA

SPR

ESSU

RE

0 500 1000 1500 2000 2500

10.00

9.00

8.00

7.00

6.00

5.00

4.00

3.00

2.00

1.00

0.00

160

140

120

100

80

60

40

20

150


35

35

PS I G

AI R/G

AS



150PSIGAIR/GAS

100PSIGAIR/G

AS

MAXFLOW(GPH)

AIR/GA

SPR

ESSU

RE

CRP1000V400


CRP750V400


CRP1000V600

Discharge Pressure PSI 0 600 2000 2500 4000 4500Gph 9.05 9.00 8.84 8.79 1 1Air Pressure PSI 35 35 60 75 120 140

CRP1000V800

Discharge Pressure PSI 0 1000 1950 5500 7300 8500gph 8.86 8.79 8.72 8.46 6.25 3Air Pressure PSI 35 35 35 88 120 140

Performance Flow Curves (cont.)

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1.2.2.3.2 Seal Material Selection

The seal material must be chosen to satisfy both the chemical compatibility and the pressures/temperatures at which you are operating

Below is a general guideline for seal material selection.

1.2.2.3 Plunger & Seal Material

1.2.2.3.1 Plunger Material Selection

The materials available vary in hardness and chemical compatibility. We offer three materials based on our many years of industry experience

with various chemicals. Hardness is a key property when selecting the proper plunger material. Our experience has shown that the harder

plunger materials not only provide longer plunger life, they also provide greater seal life. A hard plunger is a must when pumping a chemical

that is prone to crystallization or if the chemical is contaminated. Of course both of the preceding conditions will affect seal life. Below is atable that compares the chemical compatibility and hardness properties of each material.

Tough material with excellent wear resistance. Excellentchemical inertness. Good for all types of chemicals, acids,bases or solvents. Recommended for use with the harderceramic plunger and higher pressures.

Tough material with excellent wear resistance. Excellentchemical inertness. Good for all types of chemicals, acids,bases or solvents.

Tough material with excellent wear resistance. Good for waterand alcohol based chemicals. Not recommended for solvents.

Soft material with fair wear resistance. Broad chemicalcompatibility but its not to be used with ethyl or methylalcohols. Suggested only for hard to seal fluids in lowpressure applications when PE or TC will not seal.

Soft material with fair wear resistance. Limited chemical com-patibility. Used mainly in Methanol pumping at low pressure.

Soft material with fair wear resistance. Excellent chemical

compatibility. Used when Viton

is not compatible and PE or TCwill not seal.

Material has very good abrasion resistance. Excellent chemi-cal resistance to phosphate esters, good to excellent to mildacids, alkalis, silicone oils and greases, ketones and alcohols.Not recommended for petroleum oils or di-esters.

SEAL TEMP SUGGESTED

MATERIAL TYPE RANGE PRESSURE RANGE COMMENTS

TG Mechanical -30 to 180F 1,000 to 10,000 psiTeflon (Spring Loaded) -34 to 82C 207 to 690 barGraphite (High Pressure)

TC Mechanical -30 to 180F 750 to 9,000 psiTeflon (Spring Loaded) -34 to 82C 52 to 620 bar

Composite (Low Pressure)

PE Mechanical -30 to 180F 100 to 3,000 psiUHMW (Spring Loaded) -34 to 82C 6.9 to 207 bar

Polyethylene

V O-ring -10 to 200F 100 to 750 psiViton -23 to 93C 6.9 to 52 bar

BR O-ring -40 to 200F 100 to 750 psiBuna N -40 to 93C 6.9 to 52 bar

K O-ring 32 to 200F 100 to 750 psi

Kalrez

0 to 93C 6.9 to 52 bar

EPR O-ring -40 to 200F 100 to 750 psiEthylene -40 to 93C 6.9 to 52 bar

Propylene

Selecting the proper seal material for your application is important. We suggest using the harder plastic seals (PE, TC or TG) whenever possiblebecause they provide excellent wear life. The elastomers (V, BR, K or EPR) offer enhanced sealing at low pressure because they are soft and morecompliant than the plastics. However, the elastomers do not provide the same toughness or wear resistance.

DESIGNATION MATERIAL HARDNESS CHEMICAL COMPATIBILITY

CR CeramicBetween Sapphire and Diamond Excellent Chemical Inertness inon the Mohs Scale all Acids, Bases, Solvents

A 17-4 ph 40 Rc

General Corrosion-resistantStainless SteelLimited Acid Resistance

B 316 SS 28 Rc

Excellent Corrosion-resistantStainless SteelLimited Acid Resistance

We recommend the use of ceramic because of its extreme hardness and excellent chemical inertness.

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9

Physical Specifications

B

H

I

CONTROLLER

INLET 1/4" NPT (F)

BLEEDER

1/4" BARBED FITTING

E

D

F

C

G

A ACONTROLLER

E

F

C

B

P03-6S P500V400

RELAY INLET3/8" NPT (F)

RELAY

P1000V400P750V400

P1000V600

P04-6S P1000V800

DI

H

J

G

BLEEDER

1/4" BARBED FITTING

CONTROLLER

INLET 1/4" NPT (F)

Model A B C D E F G H I J WT

Inch/mm Inch/mm Inch/mm Diameter (IN) Connector Connector Inch/mm Inch/mm Inch/mm Inch/mm LBS/KG

CP125V125 4.50/114.3 9.25/235 8.12/206.2 1 7/847mm 1/4 NPT (F) 1/4 NPT (M) 13/445mm 13/445mm 6 1/4159mm n/a 7.0/ 3.2

CP250V225 6.00/152.4 11.68/296.7 11.00/279.4 2 1/263.5mm 1/4 NPT (F) 1/4 NPT (M) 2 9/1665mm 2 11/1668mm 8 7/8214mm n/a 9.0/ 4.1




CRP500V400 9.12/232 16.00/406 11.00/279.4 4 1/4108mm 1/4 NPT (F) 1/2 NPT (M) 2 5/867mm 2 13/1669mm 12 3/4324mm 9 7/16240mm 15.0/6.8

CRP750V400 9.75/247.6 16.25/412.7 11.31/287.2 4 9/16116mm 1/2 NPT (F) 3/4 NPT (M) 35/892mm 376mm 13332mm 7 9/16240mm 16.7/7.5

CRP1000V400 10.50/266.7 19.00/482.6 14.12/358.6 4 3/8111mm 1/2 NPT (F) 3/4 NPT (M) 4102mm 3 3/886mm 14 5/8365mm 8 7/8225mm 29.0/13.2

CRP1000V600 12.50/317.5 19.00/482.6 14.12/358.6 6 3/8162mm 1/2 NPT (F) 3/4 NPT (M) 4102mm 3 3/886mm 17 3/4451mm 12 1/4214mm 35.5/16.1

CRP1000V800 14.50/368.3 19.00/482.6 14.12/358.6 8 3/8213mm 1/2 NPT (F) 3/4 NPT (M) 4102mm 3 3/886mm 16406mm 11279mm 47.6/21.6

Model Plunger PistonDiameter (In.) Diameter (In.)

CP125V125 1/8 1 1/4

CP250V225 1/4 2 1/4

CP250V300 1/4 3

CP500V225 1/2 2 1/4

CP500V300 1/2 3

CRP500V400 1/2 4

CRP750V400 3/4 4

CRP1000V400 1 4

CRP1000V600 1 6

CRP1000V800 1 8

1.3 GENERAL OPERATING SEQUENCE

1.3.1 Controller

1.3.1.1 MK XII Controller

The spool spring forces the spool upward

to its highest position and unseats the top

of the pilot plug from the upper seat. The

exhaust spring forces the pilot plug

upward and seats it on the lower seat. This

blocks the air/gas exhaust port.

When high pressure air/gas enters the

supply port, it passes around and through

the spool and past the open upper seat to

the motor cylinder port.

High pressure air/gas passes through the

control passage in the controller, past the

valve stem, and into the valve body upper

chamber which causes pressure to build

up in the chamber. Because the surface

area of the upper U-cup diaphragm is

much larger than that of the middle U-cup

diaphragm, the downward force on the

spool is greater than the upward force.

This pressure pushes the spool down until

the pilot plug seats itself on the upper

valve seat, shutting off the air/gas supply.

As the spool continues to move down, it

pushes the pilot plug until the plug is

unseated from the lower valve seat and

allows the air/gas to exhaust through the

lower valve from both the motor cylinder

and the valve body volume chamber.

When the pressure in the chamber is low

enough, the spool spring starts pushing

the spool upward. The exhaust spring

pushes the pilot plug upward, and the

controller returns to its initial position.

1.3.2 Relays

1.3.2.1 PO3-6S Relay

When there is no pilot pulse (high pressure

air or gas) entering the top of the relay

from the controller, the piston spring

pushes the piston and the poppet

assembly upwards until the O-ring on top

of the poppet presses against the upper

body section, sealing the pump port from

the exhaust port. The space below the

poppet provides a path between the supply

and pump ports.

When the controller sends a pilot pulse,

the high pressure gas on top of the piston

overcomes the piston spring force, and

pushes the piston and the poppet assembly

downward until the O-ring on the bottom of

the poppet presses against the lower body

section, sealing the pump port from the

supply pressure. The space above the

poppet provides a path between the pump

and exhaust ports.

1.3.2.2 PO4-6S Relay

When there is no pilot pulse (high pressure

air or gas) entering the top of the relay

from the controller, the piston spring

pushes the piston and two poppets

attached to the piston upwards until the O-

ring on top of the upper poppet presses

against the upper body section and at the

same time the O-ring on the lower poppet

presses against the middle body section.

The upper poppet O-ring seals the number

one pump port from the number oneexhaust port; the space below provides a

path between the supply and the number

one pump ports. The lower poppet O-ring

seals the number two pump port from the

supply port; the space below provides a

path between the number two exhaust and

pump ports.

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10

When the controller sends a pilot pulse, the

high pressure gas on top of the relay piston

overcomes the piston spring force and

pushes the piston and two poppets

assemblies downward. The piston and two

poppets assemblies move down until the O-

ring on the bottom of the upper poppetpresses against the middle body section

and the O-ring on the bottom of the lower

poppet presses against the lower body

section. The upper poppet O-ring seals the

number one pump port from the supply

port; the space above provides a path

between the number one pump and

exhaust ports. The lower poppet O-ring

seals the number two pump port from the

number two exhaust port; the space below

provides a path between the number two

pump port and the supply port.

1.3.3 Pump Motor (Air Chamber)

The motor forces the piston plunger to move

alternately into and out of the pump

chamber. When the controller sends the

supply air/gas into the motor chamber

through the nipple connector, the pressure

on the piston and diaphragm overcomes

the combined force of the process fluid

pressure on the piston plunger and plunger

return spring, and pushes the plunger into

the fluid chamber. When the external

controller exhausts the air/gas, the piston

plunger return spring and process fluidpressure push the piston plunger out of the

fluid chamber.

1.3.4 Pump (Fluid Chamber)

The pump operating cycle consists of fluid

being discharged and suctioned into the

fluid chamber. During discharge, the piston

plunger moves into the pump fluid

chamber, decreasing the volume of the

chamber and raising the pressure in thechamber fluid. This higher pressure closes

the suction check valve and opens the

discharge check valve, sending the fluid

into the discharge line.

During the suction part of the cycle, the

piston plunger moves out of the fluid

chamber, increasing the volume of the

chamber and lowering the pressure of the

chamber fluid. This lower pressure opens

the suction check valve and a spring closes

the discharge check valve, sending fluid

from the suction line into the fluidchamber.

SECTION 2.0: INSTALLATION OF

PUMP AND CONTROLLER

2.1 GENERAL

Always install separate pressure regulators

in the air/gas supply lines for the controller

and the relay. Also, for the most efficient

performance of your pump assembly, we

recommend the following:

A dryer and a dump valve in the air/gas

supply line to remove any moisture from

the supply air/gas.

Isolation valves (ball type) on inlet and

discharge lines of the pump and in the

air/gas supply line to simplify

maintenance.

A check valve where the pump

discharge line joins the main process

line to prevent process fluid back flow. An inlet filter, with filtration

approximately 25 microns, on pump

suction line.

A flow meter or a rate setting gauge in

the suction line or process fluid

discharge line, if you need precise flow

rate adjustment or recording.

2.2 PUMP ASSEMBLY

Position the pump assembly with enough

space around it to allow easy access to all

components for maintenance. Install the

assembly with the pump inlet/suction

check valve pointing straight down. The

pump will not work as efficiently in any

other position since the inlet/suction check

valve has no spring.

NOTE: The pump assembly can be

installed directly in the process line

piping without any additional support

brackets.

SUPPLY BODY STROKES ELASTOMER SPOOLMODELS PRESSURE MATERIAL (SPM) STYLE

MK XIIA 35-100 PSI (2.4-6.9 Bar) 316 ss 1 - 45 Neoprene Diaphragm

MK X 35-100 PSI (2.4-6.9 Bar) 316 ss 1 - 45 Buna/TFE, Viton/TFE U-Cup

CONTROLLER SPECIFICATIONS

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11

2.4 SUPPLY RESERVOIR

Position the supply reservoir so that the

liquid level will not be less than six inches

above the inlet check valve (flooded

suction). While you can locate the reservoir

at any height above the inlet check valve

(net positive suction head), the limit is 100

psig net positive suction head, which is the

cracking pressure of the discharge check

valve. We do not recommend using the

pumps in a suction lift position since theywere not designed for such operation.

2.5 RELIEF VALVE

A safety relief valve is not necessary if the

downstream piping can withstand the

maximum pressure the pump can generate

at the available air supply pressure. The

maximum discharge pressure the pump

can generate can be taken from the

performance graphs in section 1.2.2.2.

When this pressure is reached the pump

will stop. Example: A CP250V225ATC

operating at 35 psig is capable of

generating 2520 psig. The pump will stop

pumping when the 2520 psig is reached.

SECTION 3.0: STARTUP, OPERATION,

SHUTDOWN, AND STORAGE

3.1 GENERAL

While these procedures for startup,

operation, shutdown, and storage are

simple, following them carefully and

correctly will improve the performance and

increase the life of your pump assembly.

CAUTION: To avoid damaging thecontroller valve stem, do not make a

habit of turning the pump ON and OFF

with the stroke rate control. Use the

recommended ball valve in the air/gas

supply line.

3.2 STARTUP

These startup procedures will produce a

flow rate close to what you want. For a

more precise flow rate, monitor with a flow

meter while making the final adjustment.

3.2.1 Air/Gas Supply

Before starting up your pump assembly,

make sure that the primary air/gas supply,

compressor, tank of gas, or other source, is

turned OFF. Also, set the pressure

regulator(s) to ZERO pressure.

3.2.1.1 Supply Pressure: The air/gas

supply pressure must be large enough to

produce a pump discharge pressure 200

psi higher than the process pressure.

Therefore, if the process pressure is 2800

psig, the air/gas supply should provide a

pump discharge pressure of 3000 psig. To

set the supply pressure properly, use the

performance graphs in 1.2.2.2.

NOTE: With a controller/relay

combination, the controller supply

pressure should be at the minimum

value, 35 psig (Ref. 1.2.1.1) and therelay supply pressure set per the above

procedure. Remember, the controller is

now supplying the relay and the relay is

supplying the pump. Refer to section

1.2.1.2 for the relay supply pressures.

3.2.1.2 Supply Piping: Since supplying

the proper air volume to the pump is

critical for its operation, avoid long runs of

small diameter tubing, as follows:

Locate the main air/gas supply header

as close to the pump as possible.

Use no more than five feet of 1/4tubing to supply air/gas to the controller.

Always locate the controller or relay on

the pump.

Use no more than ten feet of 1/2 tubing

to supply air/gas to the relay.

If a solenoid valve controls the pump,

locate it no more than two feet away and

use 1/2 tubing to supply air/gas to the

pump.

2.3 TYPICAL INSTALLATION

Below you will find a schematic for a typical V plunger pump installation. The key ingredients for a successful installation are: 1:Clean, dry

regulated air for the controller 2:A flooded inlet supply 3:An inlet filter 4:A rate setting gauge 5:A line check valve at the point of injection

6:Isolation valves for maintenance on each component.

Flow Tracking Controller Configuration Standard Pneumatic Controller Configuration

3-WAY

SOLENOID VALVE

FLOWOR PHMETER

PROCESS FLUID

WPC 9001,APU,

OR PLC

24VDCPULSE

4-20mASIGNAL

CHECK VALVE

FLOWMETER

TOTALIZER

PUMP

DUMPVALVE

AIR/GAS

DRYERPRESSURE

REGULATOR

AIR/GASSUPPLY

RATESETTING

GAUGE

INLET

FILTER

CHEMICALSUPPLY

600 STROKESPER MINUTE

RESETNOFLOWSELECT

PUMP1

PUMP

RATE

AUTO

MANUAL

CONTROL LOSSO F I/PMANUALADJUST

0 1 00 %

PUMP2

T OT AL

WPC9001

12345678

PUMP

&

CONTROLLER

DUMP

VALVE

AIR/GASDRYER

PRESSUREREGULATOR

AIR/GASSUPPLY

INLETFILTER

CHEMICALSUPPLY

PROCESS FLUID

CHECK VALVE

RATE

SETTINGGAUGE

FLOWMETER

TOTALIZER

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SECTION 4.0: MAINTENANCE

4.1 GENERAL

This section contains procedures for

disassembly and assembly of the

controller, pump, and check valves, plus

procedures for preventive and corrective

maintenance. To maintain the reliability,

durability, and performance of your pump

assembly and related components, it is

essential to follow these proceduresexactly and carefully.

For consistent, reliable performance,

replace any O-rings, U-cups, or other seals

that you remove. Order replacement seal

kits with detailed instructions from your


Incorporated.

12

3.2.2 Controller Stroke Rate

The controller is preset at the factory to

provide each pump the maximum number

of strokes per minute at 35 psig (Ref.

1.2.2.1 Performance Table). This setting

falls at 100 on the controller scale. At

ZERO on the scale, the pump will not cycle

and there will be no output.

To calibrate the controller stroke rate,

follow this procedure:

1. Rotate the stroke rate knob on the

controller clockwise (CW) to ZERO on

the stroke rate reference scale.

2. Turn the main air/gas supply to the

regulator(s) to ON, and adjust the

regulator to the desired pressure. (see

3.2.1.1 for determining pressure.)

3. Set the flow rate for your application by

using the controller's stroke rate knob

in combination with the pump's stroke

adjuster. (Ref. 1.2.2.1 Performance

Table)

If necessary, adjust the controller stroke

rate knob as follows:

1. Loosen the set screw and remove the

knob.

2. Adjust the valve stem to the desired

rate by hand by turning the stem

clockwise (CW) to decrease the stroke

rate or counterclockwise (CCW) to

increase the rate. Use a timer, such as

a stop watch, to determine the actualstroke rate.

3. Attach and set the knob at the desired

position on the scale (100 on scales for

45 spm, for example).

3.2.3 Pump Stroke Length

The adjuster scale for the pump's stroke

length is factory set so that a ZERO reading

equals ZERO stroke length. Calibrate the

scale as follows:

1. Turn the stroke adjuster tee set screw

counterclockwise until the stroke

adjuster knob is unlocked.2. Turn the stroke adjuster knob

counterclockwise as far as it can go.

The piston/plunger will be fully

bottomed in the pump.

3. Loosen the two screws holding the data

plate; move the data plate until the

middle of the pin is at ZERO on the

scale. Tighten the two screws.

4. Turn the stroke adjuster knob until the

middle of the pin is at the desired stroke

length on the scale.

5. Tighten the tee knob clockwise until the

stroke adjuster knob is locked.

3.3 OPERATION

3.3.1 Bleeder Plug

Shortly after the pump assembly begins

operating, the metered liquid should begin

flowing through the pump. To bleed air

trapped in the pump chamber, turn the

bleeder plug CCW about a quarter turn.

When the liquid is flowing steadily with

each pump stroke from the end of the

bleeder plug, turn it CW until the flow

stops. It is best to close the bleeder plug

when the pump is discharging and before

the suction stroke.

NOTE: To catch the escaping liquid, slip

a length of 1/4 plastic or rubber tubing

over the hose barb of the bleeder plug.

3.3.2 Stroke Rate

Set the operating stroke rate, as follows:

1. Set the stroke rate knob to a mark on

the scale that will produce a stroke rate

close to the one you want. Keep in

mind that the scale reading is only an

approximate percent indication of the

actual rate; generally the pump

maximum stroke rate will be set at 100

on the scale. NOTE: At the ZEROsetting on the controller stroke rate

scale, the pump will not stroke, but

as you rotate the knob toward 100,

the rate will increase to the

maximum strokes per minute for

each pump. (Ref. 1.2.2.1 Performance

Table) To set the stroke rate correctly,

you must time the exhausts as they

leave the bottom of the controller.

2. Count the number of pump strokes

during a one minute interval, using a

timer such as a stop watch to

determine the actual stroke rate.3. Adjust the knob to correct the stroke

rate as needed. Confirm by timing the

stroke rate.

4. Repeat the above steps until you get

the correct stroke rate. EXAMPLE: To

get a stroke rate of 22 strokes per

minute, set the knob to 50 which

should produce approximately 25

strokes per minute. Then reduce the

rate by resetting the knob to 48. If this

produces 21 strokes a minute, move

the knob to 49, which should be very

close to the 22 strokes per minute you

want. Confirm the rate by timing it.

3.4 SHUTDOWN AND STORAGE

To shut down the pump assembly, set the

pressure regulator(s) to ZERO, and turn the

air/gas supply to OFF.

To store the pump assembly or if it will not

be used for a long time, do the following:

1. Remove pump from the system.

2. Flush out the pump chamber and check

valves with water or solvent; drain and

then blow the pump dry with

compressed air.


pump when you clean it, be sure to use

a solvent compatible with the metered

fluid that will not damage the pump

seals. For a recommended solvent,

contact your distributor or Williams

Instrument Incorporated.

3. Cap off the suction and discharge

check valve ports.

4. You may leave the pump, controller,

and relay assembled, but make sure to

store them in a dry, protected place.

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13

remove. Separate upper valve body

from the lower section. (Fig. 2 & 3)

3. Lift off the upper body and diaphragm.

Lift out the inner diaphragm assembly.

Set aside. (Fig. 4 & 5)

4. Lift out the spool spring. (Fig. 6)

5. Turn lower controller body upside down.

Use a 3/16 hex wrench to unscrew

bottom plug. Remove the bottom plug,lower spring and pilot plug. (Fig. 7 & 8)

6. Return controller body as before and

unscrew lower seat with a 3/16 hex

wrench. Remove lower seat.

(Fig. 9 & 10)

Whenever you disconnect any air/gas or

fluid piping, cover all open ports in the

pump assembly to prevent dirt from

entering.

4.2 DISASSEMBLY AND ASSEMBLY

4.2.1 Required Tools and Materials

Necessary tools will vary by pump

assembly model but the following are

typical:

Adjustable wrench: 12

Belt-spanner or web wrench

Open-end wrenches: various sizes

Hex wrenches: 7/64, 1/8, 9/64,

3/16, and 5/32, 1/4, 3/8

Socket wrenches: various sizes with 2

extension

Flat-blade Screwdrivers: 1/8 (2

required) and 1/4

MK X Screwdriver in 3/16 hex Socket

Drive (Drawing 1)

Brass or plastic O-ring pick (1)

Torque wrench (15 in-lb to 122 in-lb

range)

Bench vise

Silicone grease, (Williams G321M4), or

synthetic grease (Williams GS102149)

Teflon tape 1/4

Thread sealing compound

NOTE: See 4.3 Preventive Maintenance

for inspection and replacement of partsidentified throughout these procedures.

4.2.2 Controllers

4.2.2.1 Mark XII Controller

Refer to the Mark XII Controller Parts List.

To disassemble, do the following:

1. Remove red cap. (Fig. 1)

2. The Mark XII has (4) four socket head

cap screws holding the controller

together. Use a 5/32 hex wrench to

Figure 2

Figure 3

Figure 4

Figure 5

Figure 1

Fig. 6

Fig. 7

Fig. 8

Fig. 9

Fig. 10

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14

7. To disassemble the inner diaphragm

and spool assembly, first remove outer

sleeve and mid ring by sliding past the

diaphragms towards the upper seat.

(Fig. 11, 12 & 13) Use a small screw

driver or hex wrench placed through the

inner spacer holes and with a 9/16

wrench unscrew the upper seat and

lower diaphragm. (Fig. 14) Place the top

diaphragm stop (and inner sleeve with

screw driver/hex wrench) into a soft jaw

vice with a vee notch. Lightly clamp top

reinstall the lower seat and spool

spring. Make sure the capillary holes inthe upper diaphragm, the mid ring and

the mid diaphragm are in line with the

capillary hole of the lower body. Use a

small awl or hex wrench to thread

together. Install (1) one of the (4) body

screws from the under side through the

loose parts and through the top

diaphragm. Now remove the awl and

place on top of the assembly the upper

controller body. Insure its capillary hole

is inline with the others. Loosely thread

together the (1) one body screw. Installremaining (3) three screws and torque

all to 28 - 32 inch pounds.

diaphragm stop. Unscrew inner sleeve.

(Fig. 15) Remove the mid diaphragm

from the top diaphragm stop. (Fig. 16)

Remove the lower diaphragm from the

upper seat. (Fig. 18)

8. Clean all metal parts. Inspect and or

replace all three diaphragms. To

reassemble, push the mid diaphragm

onto the top diaphragm stop. Push the

lower diaphragm onto the upper seat.

Thread the inner spacer onto these (2)

two diaphragm assemblies. With a

screw driver and 9/10 wrench, tighten

securely, but notenough to pucker the

diaphragms. Install the mid ring,

counter bore first, onto the diaphragm

assembly past the lower diaphragm and

then past the mid diaphragm. Some

maneuvering of the diaphragms will be

needed. Install the outer sleeve by

sliding past the lower diaphragm. Insure

the narrow seat on the sleeve goes

against the mid diaphragm and the

wider seat is against the lower

diaphragm. Some maneuvering of the

lower diaphragm will also be needed.

The inner assembly is now complete.

(Fig. 17 & 19)

9. To install the inner assembly into the

lower controller body, be sure to

Figure 11

Figure 12

Figure 14

Figure 13

Figure 15

Figure 16

Figure 17

Figure 18

Figure 19

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15

4.2.3 Relays: PO3-6S and PO4-6S

Refer to the appropriate Parts List.

Disassembly instructions 1 through 9 apply

to all relays, instructions 10 and 11 apply

only to the PO3-6S, and instructions 12

through 17 apply to the PO4-6S.

1. Use a 9/64 hex wrench to remove the

top cap screws (Fig. 20 & 21). Turn

screws CCW.

Figure 20

Figure 21

2. Separate the top cap with data plate

from the upper body section. (Fig. 22)

Figure 22

3. Put a 7/64 hex wrench through the

side of the relay into the upper body

exhaust port and into the hole in the

upper poppet stem. (Fig. 23)

Figure 23


piston lock screw (Fig. 23)

5. Pull out the piston, O-ring, and spring.

(Fig. 24 & 25)

Figure 29

9. Use a flat-blade screwdriver to unscrew

the lower poppet stem. (Fig. 29)

10. PO3-6S: Pull out the upper poppet and

poppet body; the poppet stem

connector bolt will remain in one of

the stems.(Fig. 30)

Figure 30

11. PO3-6S: Put a screwdriver in the holes

of the poppet O-ring retainers and pry

them off. (Fig. 31 & 32)

Figure 31

Figure 32

NOTE: You can now reassemble thePO3-6S relay by coating the poppet

stems, seals, and mating surfaces with

silicone grease, and then reversing the

above procedure.

Figure 24

Figure 25


bottom cap screws. (Fig. 26 & 27)

Figure 26

Figure 27

7. Separate the lower body section from

the upper body section. (Fig. 26 & 27)

Figure 28

8. Again, put the 7/64 hex wrench

through the hole in the upper poppet

stem. (Fig. 29)

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To continue disassembling the PO4-6S, do

the following:

12. PO4-6S: At this point, repeat step 8,

however, if the lower and middle

poppet stems should separate, modify

the rest of this procedure accordingly.

(Fig. 33 & 34)

Figure 33

Figure 34

13. PO4-6S: Separate the upper poppet

stem from the middle stem and the

poppet body. The poppet stem

connector bolt will remain on one of

the stems. (Fig. 35)

Figure 35

14. PO4-6S: Use the flat-blade

screwdriver to unscrew the lower

poppet stem.

15. PO4-6S: Pull out the middle stem and

poppet body. The poppet stem

connector bolt will remain in one of

the stems. (Fig. 35)16. PO4-6S: Put a 7/64 hex wrench or

screwdriver in the holes of the poppet

O-ring retainers and pry them off.

(Fig. 31) Then use the screwdriver to

pry out the O-rings.

Figure 40

b. Remove the motor cylinder by unfastening

the 4 to 10 screws (depending on the

pump model) holding the motor cylinder

to the faceplate. (Fig. 41)

Figure 41

c. Remove the piston plunger guide ring

and return spring. (Fig. 42 & 43)

Figure 42

Figure 43

d. Now remove the retaining ring and

spring seat. The secondary seal (and

associated backup ring if O-rings are

being used), will be found beneath the

spring seat. (Fig. 44 & 45)

Figure 36

NOTE: Reassemble the PO4-6S relay by

coating the poppet stems, seals, and

mating surfaces with silicone grease,

and then reversing the above

procedure.

4.2.4 P125, P250, P500, P750 & P1000

Pumps

4.2.4.1 Changing Plunger Seals

1. Disassembly:

a. Unscrew the pump body from the fluid

cylinder. The primary seal is visible in

the pump body. The plunger will

protrude from the pump body, through

the seal. (Fig. 37, 38, 39 & 40)

Figure 37

Figure 38

Figure 39

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Such conditions could lead to leakage or

excessive seal wear if not corrected.

Replace parts that exhibit wear.

g. Install the new seals in accordance with

the illustrations shown. Use illustration I

if your are installing the spring loaded U

cup type seals, and illustration II if you

are installing O-ring type seals. In each

case the seals and back up rings can be

easily be pushed in place using only

your fingers. Make certain the order and

position in which the components are

installed matches the illustration shown.

Also make certain the seal assemblies

are installed completely, none of the

seal assembly should protrude. NOTE:

APPLY A LITTLE GREASE FROM

GS102149 GREASE TUBE TO THE

SEALS. BACK UP RINGS AND ALL

THREADS BEFORE INSTALLING.(Figs. 52, 53, 54, 55, 56 & 57)

Figure 52

Figure 53

Figure 54

Figure 47

Figure 48

Figure 49

Figure 50

e. Remove both 1/8 NPT plugs in the

pump body so that all the old grease

and any dirt or debris can be

cleaned/flushed from the pump body.

(Fig. 51)

Figure 51

f. Thoroughly clean all internal pump

surfaces. Then inspect all metal sealing

surfaces such the seal gland and

plunger for scratches, nicks or

irregularities.

Figure 44

Figure 45The primary and secondary seals can

be removed from the pump body

assembly using either the piston-

plunger or a brass (or plastic) pick. Be

careful not to scratch the metal

sealing surfaces during the extraction

process. The piston-plunger can be

inserted alternately into each end of

the pump body assembly to push out

the opposing seal (and backup ring if

present). The brass or plastic pick can

be used to hook the seal (and backup

ring) to pull them out. Caution mustbe used to make certain that the

sealing surfaces are not scratched

during the removal of the seal and

back up ring. (Fig.46, 47, 48, 49 & 50)

Figure 46

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2. REASSEMBLY

a. Replace spring seat and retaining ring.

NOTE: The spring seat may be used

as the secondary seal installation

tool. Place the seal face down in the

cavity and push it into place with spring

seat. (Fig. 58 & 59)

Figure 58

Figure 59

b. Thread the fluid cylinder to the pump

body. The parts are designed to be

tightened using a strap type wrench

with the following torque values:

Figure 55

Figure 56

Figure 57

PUMP MODEL TORQUE (Ft-lbs)

P125V (all) 50

P250V (all) 50

P500V 225 50

P500V 300 100

P500V 400 100

P750V 400 100

P1000V (all) 100

c. Now apply Williams GS102149 synthetic

grease to the plunger, and the piston

U-cup.

d. Install the spring in the spring seat.

Then simultaneously insert and rotate

the plunger through the spring into the

pump body seals. It may be necessary

to open the bleeder plug during this

procedure to vent any fluid in fluid

cylinder.

e. Now, apply synthetic grease (GS102149)

to the internal surface of the motor

cylinder. Wrap the piston guide ring

around the piston, and while holding it

in place, slide the motor cylinder over

the piston, the U-cup and guide ring.

Align the holes in the motor cylinder

with the face plate and tighten the 4 to

10 screws removed during the

disassembly process. Assembly screw

torque is 25 in-lbs.

Retaining Ring

Spring Seat(Seal Retainer)

Secondary Seal (Upper)

Backup Ring (Spacer)

O-ring Seal

Retaining Ring Groove

Faceplate

Pump Body

Grease Access Ports

Body O-ring Seal

Backup Ring(Plunger Guide)

Primary Seal (Lower)

O-ring Seal

Fluid Cylinder

Illustration I Illustration II

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f. Lubricate the seals as follows:

1. Both 1/8 NPT plugs should have

been removed during the disassembly

of the pump to facilitate cleaning. If

this was not done, please do it now.

2. Thread the tube of grease (GS102149)

that came with the seal kit into one of

the lubrication access ports. (Fig. 60)

Figure 60

3. Now, squeeze the grease into the

lubrication cavity. Hold your finger over

the opposite lubrication cavity accesshole, alternately removing it to allow

air to escape and to feel the grease

pressurize the lube cavity. (Fig. 61)

Figure 61

4. When all the air have been expelledfrom the lubrication cavity and only

grease is exiting the opposite access

hole, the cavity is full.

5. Apply Swagelok SWAK thread sealant

to both 1/8 NPT plugs and replace in

pump housing. (Fig. 62)

Figure 62

4.2.4.2 Complete Pump Rebuild:

Although there are some differences

between the pumps, they are

disassembled and reassemble in

approximately the same way. The

procedures describe the differences.

Refer to the appropriate parts list, for

the pump you are rebuilding.(Fig.62)

Figure 63

Disassemble the pumps as follows:

1. Clamp the pump at the fluid cylinder in

a vice. Use jaw protectors to avoid

scratching the pump. (Fig. 64)

Figure 64

2. Use the belt-spanner wrench to loosen

the body from fluid cylinder. Clamp on

the body or the motor cylinder. Continue

turning the assembly by hand until the

two parts separate. (Fig. 65)

Figure 65

NOTE: The fluid cylinder of the pump

can remain installed on the plumbing if

only the pump and not the check valves

are to be serviced. Also, since the body

and the fluid cylinder are made as a

matched set, keep them together. do

not substitute parts from other pumps

of the same model.

3. Use the appropriate hex wrench to

remove the socket-head cap screws

and washers fastening the motor

cylinder to the body. If the pump has a

piston return spring it will push the two

pieces apart (exception:CRP1000V800);

if not, separate the motor cylinder from

the body and faceplate.

4. Remove the piston/plunger assembly,

piston U-cup (piston O-ring on the

P1000V800), piston guide ring and the

piston return spring (on all pumps

except the P1000V800). The piston

guide ring will fall away from the

piston. Remove the piston U-cup

(piston O-ring on the P1000V800).

(Fig.66 & 67)

Figure 66

Figure 67

NOTE: Before doing the next step, put a

piece of tape or other mark on the

outside surface of the cylinder

faceplate to align it with a body part for

reassembly.

5. Use the 5/16 open end wrench tounscrew and remove the vent plug, and

the 3/16 hex wrench to unscrew and

remove the two grease chamber plugs.

Use the appropriate hex wrench to

unscrew and remove the cap screws

and split washers fastening the cylinder

faceplate to the body. Slide the

faceplate off the body. On the

P1000V800, remove the two faceplate

O-rings. (Fig. 68, 69, 70 & 71)

Figure 68

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Figure 69

Figure 70

Figure 71

6. On the P250 and P500, use a small

screwdriver or punch to push the filter

plugs from the cylinder faceplate. (Fig.

72, 73 & 74)

Figure 72

Figure 73

Figure 74

CAUTION: Do not remove the face plate

plug from the P1000V800. The filter plug

retainers are permanently pressed into

place at the factory. DO NOT REMOVE

THEM.

7. Use a pick if necessary to remove the

body seal O-ring, the primary plunger

seal, and the plunger seal backup ring

from the body. The piston-plunger can

also be used to push out the primary

seal and backup ring by reinstalling it in

the body faceplate assembly.(Fig. 75,

76 & 77)

Figure 75

Figure 76

Figure 77

8. Clamp the body in the bench vise,

faceplate side up.

9. Use a pick or small screwdriver to lift

the end of the spring seat retainer

from the groove in the body. While

holding the end free, slide the other

pick between the retainer and the body

until the retainer is loose. (Fig.78 & 79)

Figure 78

Figure 79

10. Remove the spring seat. On the

P1000V800 remove the two spring

seat O-rings. (Fig. 80 & 81)

Figure 80

Figure 8111. Use a pick if necessary to remove the

secondary plunger seal located

beneath the spring seat or remove the

seal by installing the plunger in the

opposite end of the body-faceplate

assembly and pushing the seal out.

(Fig. 82 & 83)

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Figure 82

Figure 83

12. Use the appropriate socket wrench

(3/4 or 7/8) to unscrew the nut that

secures the piston stop and remove

the stroke adjuster assembly from the

motor cylinder. (Fig. 84, 85 & 86)

Figure 84

Figure 85

Figure 86

13. Clamp the fluid cylinder in the vise.

Use the adjustable wrench to unscrew

and remove the inlet check valve,

discharge check valve, and bleeder

plug. Before reassembling the pump,

clean all chambers, motor cylinder,

and cylinder faceplate with an

approved solvent. Contact your


Incorporated for a recommended

solvent. Also, lubricate all O-rings and

U-cups with silicone grease or

synthetic grease. (Fig. 87, 88, 89, 90

& 91)

Figure 87

Figure 88

Figure 89

Figure 90

Figure 91

Reassemble the pump as follows:

1. On all pumps except the P125 and

P1000V800, install the filter plugs in

the body.

2. On all pumps except the P125, slide

the cylinder faceplate over the body

and line up the mounting holes. Make

sure that the marked side of the

faceplate aligns with the outside of the

pump. On all pumps except the P125and P1000V800 also line up the vent

holes in the faceplate with the filter

plugs.

3. Install the screws with split

lockwashers and torque them to the

values in the table.

PUMP TORQUE (in-lb)

P125 15 - 20

P250 15 - 20

P500 15 - 20

P750 15 - 20

P1000 28 - 32

4. Clamp the body in the bench vise with

the faceplate end up.

5. For the P250, P500, P750, and

P1000V600, install a new plunger seal

in the upper area of the body by facing

the open side of the seal down toward

the grease chamber and using the

spring seat to push the seal in. For the

P125, push the seal in by hand or use a

special tool made for this purpose

(part no. WT201192).

6. On the P1000V800, put the two spring

seat O-rings on the spring seat and put

the spring seat in the body. On all

pumps except the P1000V800, align

the hole in the side of the spring seat

with the vent plug and use the 5/16

open end wrench to install the plug.

7. Separate one end of the retaining ring

and put it in the groove inside the body.

Use a finger to work the rest of the ring

into the groove until the other end is in

place.

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8. Remove the body from the bench vise.

At the threaded end of the body install

the body seal O-ring and the plunger

seal backup ring followed by the

plunger seal. Face the open side of the

seal away from the grease chamber.

9. Place the fluid cylinder in the vise with

the body mating end facing up. Use the

adjustable wrench to screw in the

suction check valve (ball end or hex

plug end into the pump), discharge

check valve, and bleeder plug. Arrows

on the check valves indicate flow

direction. Use thread sealant and teflon

tape on the suction and discharge

check valves.

10. Apply synthetic grease to the body

threads and body seal O-ring. Screw

the body into the fluid cylinder until it is

hand tight, then tighten with the web or

belt-spanner wrench per the following

torque values.

PUMP MODEL TORQUE (Ft-lbs)

P125V (all) 50

P250V (all) 50

P500V 225 50

P500V 300 100

P500V 400 100

P750V 400 100

P1000V (all) 100

11. On all pumps except the P1000V800,

put one end of the piston return spring

in the spring seat. Install the piston U-

cup (piston O-ring on the P1000V800)

on the piston. Face the open side of

the U-cup away from the plunger.

12. Apply synthetic grease liberally to the

piston/plunger assembly and inside

the motor cylinder; install the

piston/plunger assembly, without the

piston guide ring, into the body.

13. Put the piston guide ring on the piston;

while holding the ends of the guide

ring together with a finger or thumb,

slide the motor cylinder over the

piston.14. Push the motor cylinder down to the

cylinder faceplate; align the motor

cylinder mounting holes.

15. Install all the screws with split

lockwashers.

16. Use the 9/64 hex wrench on the

P125, P250, P500, and P750 and the

1/4 hex wrench on the P1000, to

torque the socket-head cap screws

and split lock washers to the values in

the table.

PUMP TORQUE (in-lb)

P125 15 - 20

P250 15 - 20

P500 15 - 20P750 15 - 20

P1000 118 - 122

17. To lubricate the seals for running, hold

a finger over one vent hole and insert

the end of the synthetic grease tube

into the other vent hole. Squeeze

synthetic grease into the grease

chamber until you feel it pressing

against your finger. Vent all the air.

Wipe off excess synthetic grease,

apply thread sealing compound to the

vent plugs, and replace them.

4.2.5 Discharge Check Valves:

All Pumps

Although there are several sizes of

discharge check valves, they are all

disassembled and reassembled the same

way. Refer to the appropriate parts list.

Disassemble the check valve as follows:

1. Clamp the check valve body in the vise.


unscrew and remove the retainer.

3. Remove the body from the vise and

dump out the spring, ball seat, ball,sleeve, and Teflon O-ring (Fig. 92)

Figure 92

4. Remove the Teflon O-ring from the

sleeve.

5. Inspect all the parts and replace them ifthey are worn.

Reassemble the check valve as follows:

1. Put the Teflon O-ring in the sleeve and

drop the sleeve, O-ring first, into the

body.

2. Drop the ball into the body.

3. Put the small end of the spring in the

spring cavity on the wide end (not the

slotted end) of the ball seat. Drop the

two parts, ball seat first, into the body.

4. Drop the retainer, spring cavity first, if it

has one, into the body and use the

appropriate hex wrench to torque to the

values in the table.

PUMP TORQUE (in-lb)

P125 230 - 240

P250/500 230 - 240

P750/P1000 118 - 122

4.2.6 Suction Check Valves: All Pumps

Although there are several sizes of check

valves with minor construction differences,

they are all disassembled and reassembled

the same way. The procedures describe

the differences. Refer to the appropriate

parts list. Disassemble the check valve as

follows:

1. Clamp the check valve body in the vise.


unscrew and remove the retainer.

(Fig. 93)

Figure 93

3. Remove the body from the vise and

dump out the ball, sleeve, and O-ring.

NOTE: On the P125 and P250 you

may need a pick or small tool to

remove the Teflon O-ring inside the

body. (Fig. 94)

Figure 94

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4. On the P500, P750 and P1000, remove

the Teflon O-ring from the sleeve.

(Fig. 95)

Figure 95

Reassemble the check valve as follows:

1. On the P500, P750 and P1000, put the

Teflon O-ring in the sleeve and drop

the sleeve, O-ring first, into the body.

On the P125 and P250, drop the O-ring

into the body, followed by the sleeve,

the end with a shoulder first.2. Drop the ball into the body.

3. On the P125 and P250, use the

appropriate hex wrench to screw the

retainer into the body. On the P125 and

P250, tighten until you feel the Teflon

O-ring resistance, then tighten another

1/4 to 1/3 turn to compress the O-ring.

On the other pumps, tighten securely.

No Loctite #277 is required.

4.3 PREVENTIVE MAINTENANCE

4.3.1 Periodic Maintenance

4.3.1.1 Once a week: Perform the

following procedures:

1. Check for process fluid leaking from the

plumbing.

2. Check for process fluid leaking from the

pump's vent hole, cylinder faceplate,

and body O-ring.

3. Check for air/gas leaks.

4. Check for loose fittings and screws.

4.3.1.2 At least once a month: Unscrew

the plug from the top of the tee fitting

between the relay and the controller; put a

few drops of Williams SF96-100 silicone

oil in the hole.

4.3.1.3 At least every six months:

Inspect the piston-plunger assembly and

seals. Replace the seals and check the

plunger for wear; replace the piston/

plunger assembly if it is scored, rough, or

discolored.

4.3.1.4 At least every twelve months:

Perform the following procedures:

1. Disassemble and inspect the pump inlet

and outlet check valves. Replace worn

parts.

2. Inspect the piston/plunger assembly,

piston return spring (on all pumps

except the P1000V800), and all seals.

Replace the piston/plunger assembly

and the seals.

4.3.2 Cleaning and Lubrication

Whenever the pump assembly is

disassembled: Clean all inside and

outside surfaces with an approved solvent,

and blow them dry with compressed air.


pump when you clean it, use a solvent

that is compatible with the process

fluid and that will not damage pump

seals. Contact your distributor or

Williams Instrument Incorporated for a

recommended solvent.

4.4 TROUBLESHOOTING

4.4.1 Proper Pump Use

When a pump is either not working or

working incorrectly, the trouble can be in

two basic areas: the pneumatic or the fluid

ends of the pump. However, since factors

other than the pump can affect its

operation, first check that the pump isbeing used properly. To help you

determine this, use the following checklist:

1. Is the air/gas supply available in

sufficient volume and at the proper

pressure?

2. Is the air/gas supply of clean

instrument quality, not dirty or wet?

3. Is a pressure regulator in use to

maintain a constant air supply?

4. Is the tube or pipe size of the air/gas

supply line correct for your pump

model?

5. Is the pump correct for the nature and

characteristics of the material(s) it

handles: composition, viscosity,

necessary line pressure, etc.?

6. Is the process fluid containerdrum, day

tank or large storage tankclean and

free of contaminants?

7. Is the filtration adequate? Disassemble

and inspect.

8. Is the size of the process fluid line

correct for the pump?

9. Is the distance between the pump and

supply air/gas correct?

10. Is the pump operating within

acceptable minimum and maximum

temperature limits?

11. Is the pump being used for more than

one purpose? Plunger seals are

affected by this.

12. Is the proper cleaning fluid being used

to flush out the pump?

13. Is there a current and accurate

service/maintenance/breakdown

record for the pump?

4.4.2 Proper Amount of Use

While answers to the questions on the

above checklist will provide considerable

information about how the pump is being

used, it is equally important to determine if

it is overworked.

Fortunately, you can use the amplification

ratio of the pump (ref. 1.1.3 Pumps) and

the process pressure (the pressure the

pump plunger is working against) to check

this. Use the following example:

Example: process pressure is 2800 psi.

Add 200 psi to the example process

pressure. This additional 200 psi will

insure that the chemical is positively

injected: 2800 psi + 200 psi = 3000

psi.

To set the air/gas supply pressure use

the performance graphs in 1.2.2.1.

From this information you can determine if

the pump is working properly. In the above

example, if the supply pressure had been

100 psi instead of 35, it would have been

excessive, resulting in premature failure of

the pump's moving parts and sealing

capabilities.

4.4.3 Troubleshooting Guide

The Troubleshooting Guide on the

following pages identifies the most

common problems, their possible causes,and corrective action for each problem.

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TROUBLESHOOTING GUIDE

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

CONTROLLER NOT Foreign material in controller Put finger over exhaust port; alternately seal & vent port toOSCILLATING clear exhaust valve.

No air/gas supply Connect pressure gauge to port opposite supply line; verifyrequired supply pressure.

Supply pressure too high or too low Reset regulator to proper pressure.

Too much pressure drop in a ir/gas l ine Increase connecting tube size or clean air l ines.

Stroke rate valve open too much Disconnect air/gas supply. Rotate stroke rate knob CCW topeg, wait 5 seconds, & rotate knob CW until it stops.DO NOT FORCE KNOB.

Reconnect supply & rotate knob CCW until oscillations start.

Adjust stroke rate to proper strokes per minute according toSpecification Sheet; loosen knob set screw, rotate knob CCWto peg, & tighten screw.

Leak between valve body & Loosen; then retighten the connection between valve &

controller body controller body. If dirty, disassemble, wipe clean andreassemble.

Continuous air flow from controller Inspect & replace damaged lower seat and pilot plug.exhaust port (Pilot plug not seatingproperly)

Air flowing from equal izer hole on Inspect & replace ruptured or improperly seated seals.side of lower control body

Put finger over exhaust port; alternately seal & vent port toclear exhaust valve.

Broken pilot plug, exhaust spring, Replace damaged parts.or spool return spring

Excessive water in controller Install an air/gas dryer or separator in supply line.

RELAY NOT OPERATING Broken piston return spring Replace return spring. See page 15

Poppet stem loosened from connector bolt Tighten poppet stem to connector bolt. See page 15

Air blow-by caused by poorly sealed O-rings Improve quality of air supply and clean dirt from unit.Replace O-rings if damaged.

Inadequate air supply Check air regulator for proper pressure.

PLUNGER NOT STROKING Controller control knob set at ZERO Turn knob to proper setting on dial.

Air/gas supply turned OFF Open valve to allow air supply to flow to controller.

Broken motor return spring Replace return spring.

Plunger stuck due to tight or dry seal If seal is swollen, check its chemical compat ibi li ty withprocess fluid; replace with compatible seal material.

If seal is dry, lubricate & fill reservoir with grease.

Plunger bottomed Readjust plunger stroke length. Replace return spring ifbroken.

Excessive grease between cylinder and Remove excess grease. Piston seal may be leaking; checkfaceplate and replace if necessary.

Air/gas supply pressure too low to Increase supply pressure to controller or relay.overcome process line pressure

Discharge or suction line plugged Clean the lines.

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PLUNGER NOT STROKING Air/gas flow to controller too low (controller Install a larger capacity regulator or supply line. Vent supply(Cont.) locked up and will not cycle) side of controller and try to start pump at slowest speed;

increase speed slowly if controller starts to cycle.

Motor cylinder-air piston blow-by Check piston seal; replace as needed.

Check motor cylinder surface for damage from dirt or sand;install clean filters on bottom of cylinder faceplate. Replacecylinder if necessary.

LOW PUMP OUTPUT Viscosity of the chemical being pumped Review and enlarge size of supply and discharge lines totoo high. improve flow of chemical.

Pump mounted too high to suck adequate Remount pump to create a flooded suction (six inchsupply of chemical to fluid cylinder minimum).

Pump appears sluggish in stroking. Piston Remount pump as close to controller and relay as possiblenot returning all the way. to allow the controller and relay to exhaust quickly. Check

for ice in exhaust port.

Suction lift condition inadequate. Change tank elevation to get flooded suction if change notpossible, add foot valve at end of suction line, and increase

suction line diameter.

Blocked suction filter Clean or replace filter element.

Supply and discharge lines too small. Install correct tubing size.See pump sluggish

Erratic controller operation Rebuild, clean and lubricate controller; add air inlet filter orair/gas dryer.

Check valves leaking or contaminated. Rebuild, replace damaged parts.Loss of pump capacity

Improper chemical supply Make sure top of chemical supply tank is ventedto atmosphere or pressurized.

PROCESS FLUID IN Premature wear on plunger seals from Calculate proper speed and air supply pressure. (Refer toGREASE CHAMBER OR excessive pump speed amplification ratio principle.) Replace seals and plunger.

LEAKING FROM BODYOR CYLINDER Foreign material in process fluid Check to see if chemical supply is clean; if not, installFACEPLATE VENT HOLE chemical filter in supply line.

Seals incorrectly assembled or damaged Refer to instructions for install ing seals.during installation

Plunger nicked, burred or scratched Replace plunger and seals.

PROCESS FLUID IN Seal or plunger materials not compatible Refer to compatibility charts; contact distributor orGREASE CHAMBER OR with process fluid Williams Instrument IncorporatedLEAKING FROM BODYOR CYLINDER Crystallized chemical on plunger Maintain lubricant and decrease time between inspections.FACEPLATE VENT HOLE scoring seal(cont.)

Lubricant incompatible with process fluid Change lubricant; contact distributor or WilliamsInstrument Incorporated

NO PUMP DISCHARGE Suction check valve or discharge check Clean or replace check valves.valve not seating

Suction or discharge line clogged Inspect line for closed connections or valves.

Air entering suction line Tighten fittings; Inspect and replace sealants.

Pump vapor locked Open bleeder plug and prime pump.

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

25

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